World Leaders in Combustion Management Solutions Module Gas Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Autoflame Training, 2011 Mk7 EGA (Technical Training)

World Leaders in Combustion Management Solutions Module Gas Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems Sampling and display O 2, CO 2, CO, NO and SO 2 or NO 2 Exhaust temperature Combustion efficiency 3 parameter trim O 2, CO 2, CO Limits O 2, CO 2, CO, NO and exhaust gas temperature

World Leaders in Combustion Management Solutions Module EGA Trim Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems Stand alone/trim function Emissions levels can be accessed via: 10.4” Touch screen display Micro Modulation unit Six 4-20mA signals Data Transfer Interface (DTI & CEMS monitoring) PC (personal computer) BMS (building management system) PLC

World Leaders in Combustion Management Solutions Module EGA Trim Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems 1.Improve combustion 2.Increase efficiency 3.Reduce fuel consumption 4.Reduce Cost- up to 2% has been recorded 5.The most important reason- IMPROVED SAFETY

World Leaders in Combustion Management Solutions Module EGA Trim Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems 1.E.G.A. 3 parameter trim O 2, CO 2 and CO Trims because of fluctuations in ambient conditions 2.Variations in stack pressure or barometric conditions or small changes in gas pressure/BTU content Minute corrections to the air damper Or minute corrections to the fan speed drive

World Leaders in Combustion Management Solutions EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems

World Leaders in Combustion Management Solutions Module EGA Trim Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems Problems with O 2 trim 1. If only O 2 is measured and trimmed on then there is no measurement as to what the CO or NOx readings are 2.O 2 readings seem correct but what is actually happening? Changes in ambient conditions can cause the CO to rise significantly (>>100ppm) even though the O 2 reads well- O 2 trim does not correct Leaks through the boiler- small gaps in the boiler shell (around joints) can lead to increased air being induced into the boiler Higher O 2 readings from atmosphere so the system starts to trim, even though the combustion may be fine Combustion becomes unstable and dangerous CO levels (>>500ppm), higher NOx levels, O 2 readings correct Actual combustion O 2 readings around 0-0.5%- very dangerous!!

World Leaders in Combustion Management Solutions Module EGA Trim Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems Parameter 74

World Leaders in Combustion Management Solutions Module EGA Trim Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems Combustion Map

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Limits of Combustion

World Leaders in Combustion Management Solutions EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems

World Leaders in Combustion Management Solutions EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 sampling screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems 45 DEGREES INCORRECT CORRECT SAMPLE TUBE PROBE Tubing Maximum length- 10mMaximum length- 10m Diameter- 2mmDiameter- 2mm No lower pointsNo lower points Probe positioning 45 0 angle into flue Check for leaks 1.5” BSP socket Error 20- tube blockage

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems E.G.A. Positioning 10m to sampling probe Cool environment (41 0 F – F (5 0 C – 40 0 C)) Exhaust gases- where do they go? Re-calibrates on contaminated gases External environmental enclosure (ENC1008) Non-standard ambient conditions Extreme environments

World Leaders in Combustion Management Solutions Module Gas Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Sample In Thermocouple I/P Sample Inlet Pinch Valve (3) NO Cell CO/NO Bypass Pinch Valve (1) SO 2 Cell SO 2 Pinch Valve (2) CO Cell O 2 Cell Pum p SO 2 Pump Fan Pressure Switch Drain Solenoid Vacuum Switch LED Bank CO 2 Cell Chiller Block Filter

World Leaders in Combustion Management Solutions Module Gas Setup Introduction The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Options 12- E.G.A. setup Monitoring only Trim functionality E.G.A. not optioned 19/20/21- upper offset limits % O 2, CO 2 : ppm CO 22/23- lower offset limit % O 2, CO 2 25/26/27- absolute value % O 2, CO 2 : ppm CO 28- trim threshold 36- sensor selection for NO, SO 2, NO 2 cells

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems Parameters 4- allows readings to settle during commissioning 8- wash out period 9- auto commission time 11- air flush time 12- CO included for trim function 13- air damper movement during auto commission 14- fuel valve movement 16- time between E.G.A. self calibrations

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Combustion Management Systems Parameters (continued) 17- number of trims before error 18- air damper movement during operation 24- E.G.A. calibration time 25- time interval between samples 26- number of samples per trim cycle 27- minimum operating temperature 28- maximum operating temperature 44- O 2 window for no further trim 45- CO 2 window for no further trim

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Serial cable link between PC and E.G.A. DOS based program Usable with Windows XP (Technical Bulletin #14) Press F1 for help menu on the program Pinch valve configuration

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots 1.O 2 range adjustable, e.g. 4mA (0%) – 20mA (20.9%) 2.CO 2 range adjustable 3.CO range adjustable, e.g. 4mA (0ppm) – 20mA (999ppm) 4.NO range adjustable 5.SO 2 range adjustable 6.Exhaust gas temperature 7.Efficiency/nett/gross 8.Input for ambient air temperature 9.Air temperature input, e.g. 4mA (32 0 F(0 0 C)) – 20mA (700 0 F(372 0 C)) 10.E.G.A. unit air temperature ambient 11.Smoke density auxiliary input/output

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Error code on MM display 01- no communications to the EGA Check wiring Is the system grounded? 20- pump failure Sampling blockage- check inlet to E.G.A. Isolation of each section

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Error code on MM display 21- O 2 cell failure Check voltages Re-calibration Are there any leaks on the tubing (pinch valves)? O 2 cell reads 20.9% Check all the tubing is airtight Is the sample tube blocked? Air solenoid? Leak on flue?

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Levels of repair/service 1- Minor repair/service Cleaning, testing and re-calibration New pump, tubing plus cells if required 2- Significant repair Plus replacement of damaged components, cells, e.t.c. 3- Service exchange Replacement of E.G.A. for a fully repaired, tested and calibrated unit 4- Beyond Economical Repair (BER)

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots The New Mk7 EGA

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Sampling Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Sampling Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Sampling Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Sampling Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Gas History Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Setup Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Setup Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Setup Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Cell Status Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Cell Status Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Settings Screen

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Settings Screen, Operating Mode

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Settings Screen, Operating Mode

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Settings Screen, Calibration Code

World Leaders in Combustion Management Solutions Module Gas Setup Sampling The Mk7 E.G.A Cell Status Further Information Settings EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Mk7 EGA – Fault History

World Leaders in Combustion Management Solutions EGA Trim Limits Introduction The Mk7 E.G.A Good Practice Troubleshooting Software Screenshots Thank you for listening.